Three dimensional interpenetrating networks of macroscopic assemblages of randomly oriented carbon fibrils and organic polymers

Abstract

The invention relates to an interpenetrating network of carbon fibrils and a polymer, which comprises a rigidized, three-dimensional macroscopic assemblage of a multiplicity of randomly oriented carbon fibrils and an innerpenetrating mass of an organic polymer. The invention also relates to methods of making and using such innerpenetrating networks.

What is claimed is: 
     
       1. An interpenetrating network of carbon fibrils and a polymer comprising: (a) a rigidized, three dimensional macroscopic assemblage of a multiplicity of randomly oriented carbon fibrils, and   (b) an interpenetrating mass of a polymer infiltrated within said assemblage.   
     
     
       2. An interpenetrating network of carbon fibrils and a polymer comprising: (a) a rigidized, three-dimensional, macroscopic assemblage of a multiplicity of randomly oriented carbon fibrils, said fibrils being substantially cylindrical with a substantially constant diameter, having c-axes substantially perpendicular to their cylindrical axis, being substantially free of pyrolytically deposited carbon and having a diameter between about 3.5 and 70 nanometers, and   (b) an interpenetrating mass of an organic polymer infiltrated within said assemblage.   
     
     
       3. An interpenetrating network of carbon fibrils and a polymer produced by a method comprising the steps of: (a) forming a rigidized, three dimensional, porous, macroscopic assemblage of a multiplicity of randomly oriented carbon fibrils;   (b) introducing a liquid or gas phase monomer into the interior of said assemblage together with a polymerization catalyst or initiator; and   (c) causing said monomer to polymerize within said assemblage thereby forming said interpenetrating network of carbon fibrils and polymer, wherein the polymer infiltrated with said assemblage.   
     
     
       4. An interpenetrating network of carbon fibrils and a polymer produced by a method comprising the steps of: (a) forming a rigidized, three-dimensional, porous, macroscopic assemblage of a multiplicity of randomly oriented carbon fibrils, said fibrils being substantially cylindrical with a substantially constant diameter, having c-axes substantially perpendicular to their cylindrical axis, being substantially free of pyrolytically deposited carbon and having a diameter between about 3.5 and 70 nanometers;   (b) introducing a liquid or gas phase organic monomer into the porous interior of said assemblage together with a Ziegler catalyst or an initiator; and   (c) causing said monomer to polymerize within said assemblage thereby forming said interpenetrating network of carbon fibrils and polymer, wherein the polymer infiltrated within said assemblage.   
     
     
       5. The interpenetrating network of claim 1, wherein said carbon fibrils have an average diameter less than 1000 nm. 
     
     
       6. The interpenetrating network of claim 1, wherein said carbon fibrils have an average diameter less than 200 nm. 
     
     
       7. The interpenetrating network of claim 1, wherein said carbon fibrils have an average diameter less than 100 nm. 
     
     
       8. The interpenetrating network of claim 1, wherein said carbon fibrils have diameters in the range of 3.5 to 70 nm. 
     
     
       9. The interpenetrating network of claim 1, wherein said carbon fibrils are free of a continuous thermal carbon overcoat. 
     
     
       10. The interpenetrating network of claim 1, wherein said rigidized, three dimensional, macroscopic assemblage is prepared by dispersing carbon fibrils an aqueous or organic media and then removing the media to form said assemblage. 
     
     
       11. The interpenetrating network of claim 1, wherein said rigidized, three dimensional, macroscopic assemblage is prepared by intimately mixing fibrils with a glue to form said rigidized assemblage. 
     
     
       12. The interpenetrating network of claim 1, wherein said interpenetrating mass of polymer is prepared by introducing a monomer into the rigidized assemblage together with a suitable polymerization catalyst or initiator and causing the polymerization to take place within the assemblage. 
     
     
       13. The interpenetrating network of claim 1, wherein said polymer comprises monomers selected from the group consisting of styrene, substituted styrene, methyl methacrylate, alpha olefins, substituted alpha olefins or mixtures thereof. 
     
     
       14. The interpenetrating network of claim 1, wherein said interpenetrating network is substantially free of void spaces. 
     
     
       15. The interpenetrating network of claim 12, wherein said monomer is a gas. 
     
     
       16. The interpenetrating network of claim 12, wherein said monomer is a liquid. 
     
     
       17. The interpenetrating network of claim 1, wherein said rigidized, three dimensional, porous, macroscopic assemblage is formed from oxidized carbon fibrils. 
     
     
       18. The interpenetrating network of claim 3, wherein step (c) comprises evenly and thoroughly distributing said polymerization catalyst or initiator throughout the interior of the assemblage.